Products Finishing

OCT 2013

Products Finishing magazine is the No. 1 industrial finishing publication in the world. We keep our readers informed about the latest news and trends in plating, painting, powder coating, anodizing, electrocoating, parts cleaning, and pretreatment.

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Page 26 of 115

WHeels of fortune The wheels are run through the 2,000-foot line at 4 feet per minute and conveyed to a powder primer application using four automatic guns mounted on vertical reciprocators. Online Video See video of SB Manufacturing's new wheel coating operation. Scan the QR code or visit Starting with Scrap The SB manufacturing process starts with the melting of scrap aluminum, and then the liquid metal is transferred and injected into four, low-pressure die-cast molding machines. After flash is removed from the castings and inspected, the castings are heat-treated, machined and sent into a 12-stage wash operation set up by Chemetall to enhance performance. According to Tolsma, the eight-hour wash process was developed to replace hexavalent chrome technology for prepaint aluminum preparation. He says it leaves a colorless, non-staining film that performs well with both full-painted and machine-faced wheels. Chemetall set the system up with a cleaner stage, a double rinse with virgin RO halos, a deoxidizer stage, another double rinse with virgin RO halos, then Chemetall's Gardobond pretreatment, which is an aluminum conditioner and the first of a two-step conversion coating. After a double rinse with virgin DI halos, Chemetall's secondstep conversion coating, a self-assembling-molecules process known as SAM, is applied and followed by another double rinse with virgin DI halos. Tolsma says SB chose the Chemetall process because it is a "green" process that has been in use since 2002 on more than 100 million wheels with equivalent or better field performance than hex-chrome technology for pre-paint aluminum preparation. "The oven not only cures the powder primer, but it does double-duty to age-harden the wheels to the correct hardness," Jacobsen says. When the primer is cured, the wheels move into a new waterbased liquid finishing operation supplied by Finishing Brands that features a Ransburg Aerobell high-speed rotary atomizer mounted on a short-stroke reciprocator that can operate to speeds as fast as 60,000 rpm. Jacobsen says the rotary bell produces a very fine atomization and transfer efficiency of 90+ percent, which he says virtually eliminates overspray. A Ransburg Control Pac is used to control the high-voltage, shape-air turbine speed and digital outputs to trigger the bell, and a PLC system is used for automatic part tracking and triggering of the applicators. The fluid flow and automatic color change is controlled by a single-channel Ransflow metering Powder and Liquid Finishing The finishing process starts with an Akzo Nobel water-based epoxy powder coating, followed by a liquid topcoat and then an acrylic powder clear coat. The wheels are run through the 2,000-foot line at 4 feet per minute and conveyed to a powder primer application using four automatic guns mounted on vertical reciprocators. This is followed by a trip through a 20-foot infrared (IR) oven that has three separate lines. SB had Finishing Brands install all new equipment to manage the system, including products such as DeVilbiss, Ransburg, BGK and Binks spray-finishing, fluid-handling and electrostatic-spray equipment. PRODUCTS FINISHING — 25

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